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Haldor TopsøeCatalyzing your business
Aldo PeirettiChemicals General Manager Latin AmericaJornada sobre Gas de Síntesis y sus Derivados – Instituto Petroquimico Argentino (IPA)9 October 2013, Buenos Aires
¡ Established 1940¡ Ownership: Haldor Topsøe Holding A/S
(100%)¡ Annual turnover (2012): ~700 MM EUR
(~950 MM USD)¡ Number of employees ~2300
¡ Group management– Business units: Chemical,
Environmental, Refinery andNew Business
– Engineering Production– Catalyst Production– R&D
Topsøe Group’s headquartersin Lyngby, Denmark
Dr. Haldor Topsøe“The corporate world in itself
means nothing unless itimproves the lives of people
and the conditions in thepoor countries”
"El mundo corporativo en símismo no significa nada amenos que mejore la vida
de las personas y lascondiciones en los países
pobres"
Topsøe- A global supplier of catalysts and technologies
Copenhagen Moscow
BeijingBahrain
New Delhi
Buenos Aires
Alberta
Kuala Lumpur
Los Angeles Houston
Headquarters Topsøe offices Research
Production Engineering Sale & Marketing
SubsidiariesHaldor Topsoe, Inc.Haldor Topsøe International A/S, DenmarkHaldor Topsoe India Pvt. Ltd. IndiaZAO Haldor Topsøe, RussiaSubcontinent Ammonia Investment Company ApS (SAICA)Topsoe Fuel Cell A/S, Denmark
Rio
Cape Town
Tokyo
… and a leading market player¡ Market share between 15-25% for established products
¡ Supplier of solutions for 50% of new ammonia plants builtwithin the last decade
¡ More than 60% of ammonia is produced worldwide on Topsøecatalyst
¡ Supplier for 40% of catalysts for production of ultra-low sulfurdiesel
¡ > 30% market share of hydrogen catalysts
¡ Leading environmental catalysts and technologies
¡ > 35% market share of sulfuric acid catalysts
¡ 30% market share of FCC pretreatment catalysts
In short- Topsøe is dedicated to
Presentation outline¡ Syn-Gas Technologies
– Conventional scheme for Ammonia / Hydrogen / Methanol
– Developments
– Benefits
¡ Ammonia & Methanol Co-production
¡ New Technologies
– TIGAS
– SNG
¡ References
Technologies¡ Syngas technologies
– Ammonia
– Hydrogen
– Methanol
– Formaldehyde
– DME
– TREMP™ (SNG)
– TIGAS
Ammonia conventional schemeReformingDesulphurisation Shift
Process steam
Natural gas
Process air
Stack
Purge gas
Ammoniaproduct Ammonia synthesis
CO2-removal
Processcond.Methanation
Hydrogen typical flowsheet
Fuel gas
BFW
Combustion air
Flue gas
LPG/naphtha.
NG
S-removalPre-
reformerTubularreformer Shift PSA
(pressureswing
adsorption)
H2
Steam
Steam
Makeupcomp.
Methanolreactor
Raw methanol
Condensate
Steam reformer
Sulphur remov.
Sulphur removal
Naturalgas
Prereformer
Methanol production by one-step reforming
Steam
Pre-reformer
Secondaryreformer
Steam
Steam
Oxygen
Makeupcomp.
Light ends to fuel
Methanolreactor
Water
Rawmethanol
Raw methanol storage
Condensate
Steam reformer
Sulphur sat. removal
Hydrogenator
Naturalgas
Productmethanol
Methanol production by two-step reforming
Methanol production by ATROxygen/steam
Steam Steam
Raw methanol
Natural gas
Water CondensatePurge
gasHydrogenrecovery
Methanolreactor
Autothermalreformer
Hydro-genator
Sulphurremoval
Saturator Pre-reformer
Makeupcomp.
Rec.comp.
Economy of scale
Capacity
Cos
t
Tubular reformingOxygen plant
Naturalgas
Syngas
Naturalgas
AirOxygen
Syngas
Naturalgas
AirOxygen
Syngas
¡ One-step reforming– S/C ratio ~ 1.8 - 2.5
– up to ~ 2,500 MTPD
¡ Two-step reforming– S/C ratio 1.5 - 1.8
– 1,500 – 6,000 MTPD
¡ Autothermal reforming– S/C ratio 0.6
– > 5,000 MTPD.
Developments¡ High flux primary reformer with Prereformer
– better tube materialsè saving in number of tubes
¡ HTCR (Haldor Topsøe Convection Reformer)
¡ HTER (Haldor Topsøe Exchange Reformer)
¡ TBR (Topsøe Bayonet Reformer)
¡ New burner in secondary reformer
¡ New configuration on NH3 converters S-300 & S-350
¡ Improved catalysts
Today’s steam reforming technologyRadiant wall reformer (SMR)
15,000-200,000 Nm3/hConvection reformer (HTCR)
5,000-50,000 Nm3/h
Exchange reformer (HTER)+ ≤40,000 Nm3/h
Bayonet reformer (TBR)5,000-170,000 Nm3/h
Prereformer
Conventional scheme - prereformerReformingDesulphurisation Shift
Process steam
Natural gas
Process air
Stack
Purge gas
Ammoniaproduct Ammonia synthesis
Prereforming (optional)
CO2-removal
Processcond.Methanation
Prereformer benefits¡ Feedstock flexibility
¡ Reduced NG fuel firing
¡ Reduced steam production
¡ Reduced primary reformersize
¡ Potential for higher heat flux in primary reformer
¡ Increased run length/reliability of reformer and shiftcatalyst systems
HTCR - Convection Reformer
Tube bundle
Burner chamber
flue gas inlet
gas outlet process gas inletprocess gas outlet
flue gas outlet
The HTCR benefits
¡ High efficiency and no steam export
¡ High operating reliability
¡ Compact lay-out
¡ Short lead time
HTCR tube bundle
HTCR reformer tube bundle for 27 MMSCFD unit
HTCR twinä process
Feed
3 x
H2Steam
S-removal Prereformer HTCR twin reformer Shift PSA
Fuel
Flue gas Off-gas
Combustion air
HTER - Exchange ReformerFeed gas
Product gas
SMR effluent
Conventional scheme - HTERReformingDesulphurisation Shift
Process steam
Natural gas
Process air
Stack
Purge gas
Ammoniaproduct Ammonia synthesis
Prereforming (optional)
(optional)
CO2-removal
MethanationProcesscond.
HTER
HTER-p flowsheetSecondary reformerTubular reformer
Processsteam
HTER-p
Process air
Desulp.natural gas
HTER benefits¡ Smaller size primary reformer
¡ Reduced NG fuel firing
¡ Reduced steam production
¡ Reduced CO2 emissions to atmosphere
¡ ~ 10-25% reforming capacity revamp option
TBR – Topsøe Bayonet Reformer
Reformer tube
Catalyst
Center tube
Radiant wall Radiant wall
Process gas outlet
Process gas inlet
Bayonet Reformer benefits
¡ Improvement of traditional SMR technology
¡ Low or eliminated steam export
¡ High hydrocarbon efficiency
¡ Capital cost savings
¡ Feed + fuel savings
Bayonetreformer
Pre-reformer
S-removal
Feed
Stack
Combustion air
Fuel
Shift PSA
H2
The TBR flowsheet
Nozzle Burner benefits¡ Homogeneous gas and temperature distribution at the
inlet to the catalyst bed
¡ Effective mixing at the burner nozzles
¡ Low metal temperatures of the burner
¡ Less maintenance
Conventional scheme – S-50 ConverterReformingDesulphurisation Shift
Process steam
Natural gas
Process air
Stack
Purge gas
Ammoniaproduct Ammonia synthesis
Prereforming (optional)
(optional)
(optional)
CO2-removal
HTER
MethanationProcesscond.
Conventional scheme – S-50 Converter¡ Higher conversion è higher production
¡ Higher energy efficiency– Lower loop pressure
– Lower compressor power
– Higher steam generation
Recent catalyst developments
Prereforming catalyst¡ Feedstock flexibility
¡ High activity
AR-401
Hydrogenation¡ High activity
¡ Low pressure drop
Sulphur absorbent¡ High sulphur absorption capacity
¡ Hydrogenation activity
HTZ-51
TK-261
Recent catalyst developments
Methanol synthesis catalyst¡ Increased production & long lifetime
¡ Superior activity with lower by product level
Reforming catalyst¡ Alkali promotion technology
¡ Superior resistance to carbon formation
Shift catalyst¡ Superior high and stable activity
¡ Outstanding poison resistance
RK-400
LK-853 FENCE
MK-151 FENCE
Ammonia & Methanol
Co-production Technology
Ammonia and methanol production
CO2 removal AmmoniasynthesisMethanation
AmmoniaShiftPrimary
reformingSecondaryreforming
Naturalgas
Ammonia plant
Autothermalreforming Distillation
MethanolMethanolsynthesis
Airseparation
Oxygen
Primaryreforming
Naturalgas
Methanol plant
Co-production plant
Primaryreforming
Secondaryreforming
DistillationNaturalgas
Methanol
Methanolsynthesis
Methanation Ammoniasynthesis
Ammonia
Ammonia and methanol production
CO2 removalShiftPrimaryreforming
Secondaryreforming
Naturalgas
Co-production plant
Methanolsynthesis
AmmoniasynthesisMethanation
Ammonia
Methanol
Co-production plant
Primaryreforming
Secondaryreforming
DistillationNaturalgas
Methanol
Methanolsynthesis
Methanation Ammoniasynthesis
Ammonia
Integrated methanol, ammonia, urea plantProcess steam
Natural gas
Process air
StackPurge gas
Ammoniaproduct
Methanol product
CO2
Oxygen
Ammonia synthesis Methanation Methanol synthesis CO2 removal
Desulfurization Reforming Shift
Summary co-production technology¡ Flexibility in adjustment of the ammonia and methanol production capacities
¡ Two-step reforming unit using optional enriched air in the secondary reformer
¡ Once-through methanol synthesis at standard pressure
¡ High pressure methanator
¡ Low energy consumption
¡ The simple layout increases reliability
¡ Low CO2 emissions (reduced by ~36% from CO2 section in ammonia plant & ~20%from reformer flue gas stack if an HTER is introduced)
¡ Results in lower investment cost than individual plants
¡ Well-proven scheme with 5 plants in operation
¡ First reference has been in operation since 1993 – and the latest referenceplant is under construction in Russia
¡ Topsøe supplies full range of technology and catalysts
Topsøe experience list co-production plantsLocation Methanol capacity
MTPDAmmonia capacity
MTPDStart-up
Middle East 72 286 1993
USA 363 600 1994
China 120 600 1999
Malaysia 200 1,125 1999
China 136 314 2003
Russia 670 1,382 2015 (exp.)
Middle East 3,000 900 2015 (exp.)
Middle East 3,000 900 2015 (exp.)
Russia 1350 415 2016(exp.)
New Technologies
New technologies¡ TIGAS
– Topsøe Integrated GAsolineSynthesis
– Methanol to gasoline
– Syngas to gasoline
¡ TREMP– Topsøe REcycle Methanation
Process
– Production of SNG (SyntheticNatural Gas)
A brief overview of the TIGAS technology¡ Topsøe Intergrated GAsoline
Synthesis
¡ Raw material for TIGAS– Methanol
– DME
– Syngas
¡ The product has 88-92 octane
¡ The TIGAS product can be useddirectly in the gasoline pool
¡ The process has been demonstratedin large scale for 4 years
¡ Methanol-to-gasoline (MTG)
¡ Syngas-to-gasoline (STG)
Synthesis gas Methanolsynthesis
Gasoline
C3-C4
Water
TIGAS
Process options for TIGAS
Synthesis gas MeOH/DMEsynthesis
Gasoline
C3-C4
Water
TIGAS
A brief overview of the TREMP technology¡ SNG generated by methanation
of syngas– CO + 3H2 → CH4 + H2O
– CO2 + 4H4 → CH4 + 2H2O
¡ Typical raw material for thesyngas– biomass, waste, coal, petcoke
¡ Markets for SNG– Where NG resources limited
– Where the raw materials areabundant
– Strategic energy sourcing
First modern SNG plant¡ Largest single train SNG plant
– 1.4 billion Nm3/year– Contract awarded in September 2009
¡ Contract includes:– Licence– Engineering– Catalyst– Services– Procurement assistance
¡ Start-up in autumn 2013¡ Xinjiang Qinghua Coal Based Co. Ltd. in China
Principales clientes en America Latina¡ PETROBRAS (ULSD, Hidrógeno, WSA/SNOX, Amoniaco)
- Refinerias RNEST, REFAP, REVAP, REGAP, REDUC, UFN-5, etc.
¡ PEMEX (8 nuevas unidades ULSD, Hidrógeno, Amoníaco)
¡ PDVSA (Petropiar, Petrocedeño, Amuay, Cardon)
¡ PEQUIVEN (FertiNitro, Metor, SuperMetanol, Morón, El Tablazo)
¡ YPF (Lujan de Cuyo: ULSD, Hidrógeno, WSA – Huincul: Metanol)
¡ PETROPERU (Refinería Talara: ULSD, Hidrógeno y WSA)
¡ PROFERTIL (Amoniaco)
¡ ENAP (Refineria BioBio y Aconcagua, catalizadores para Hidrocraqueo)
¡ STAATSOLIE, Suriname (Hidrógeno y WSA)
¡ ANCAP (ULSD)
¡ MOLYMET (WSA)
¡ CUVEMPEQ (Amoníaco)
Haldor Topsøe en Argentina¡ PROFERTIL, Bahia Blanca – Planta de amoniaco, 2,000 mtpd
¡ AIR LIQUIDE, Campana – Planta de Hidrogeno, 15,000 Nm3/h
¡ ENSI – Planta de Agua Pesada, Neuquen – Sintesis de NH3 y crackers de NH3
¡ YPF Refineria Lujan de Cuyo – Planta de Hidrogeno, 6,000 Nm3/h
¡ YPF Planta de Metanol, Plaza Huincul - Catalizadores Metanol
¡ YPF Refineria Lujan de Cuyo, Internos Rxs y catalizadores de Hidrotratamiento -Catalizadores hidrocraqueo ISOMAX - Reactor Design Package & Internos Rxs &catalizadores para Unidad HDS-3 – Catalizadores planta de hidrogeno – BEDP paraplanta WSA
¡ YPF Refineria La Plata – Internos Rxs HTG – Hidrotratamiento de gas oil – BEDPpara planta WSA
¡ Axion Energy, Campana – NHT catalysts
¡ Bunge, Campana – Catalizadores para planta de amoniaco
¡ Alto Paraná, San Martin – Catalizadores para la Sintesis de Metanol
¡ Catalizadores para Acido Sulfurico en DGFM / Meranol / Akzo Nobel
Gracias por su atención
